Packaging system for vertically packaged rolls

ABSTRACT

A packaging and stabilizing system and method for creating a pallet of vertically aligned rolls of material. The packaging system includes a plurality of individual interlocking devices that each extend between the cores of a pair of rolls on the pallet. The interlocking devices are installed to create a lattice pattern between the rolls on the pallet such that the rolls are stabilized and prevented from tipping. Each individual roll of the pallet can be removed by first removing the interlocking devices connecting the roll to the remaining rolls in the pallet. Once the interlocking devices are removed, the roll can be removed without compromising the stability of the remaining rolls on the pallet.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application is based on and claims priority to U.S. Provisional Patent Application Serial No. 60/400,653 filed on Aug. 1, 2002.

FIELD OF THE INVENTION

[0002] The present invention relates to a packaging system for use in packaging vertically-oriented rolls of material. More specifically, the present invention relates to a packaging system for interlocking vertically-oriented rolls of material on a pallet such that the rolls of material can be individually stacked and later removed while the remainder of the rolls on the pallet are stabilized.

BACKGROUND OF THE INVENTION

[0003] Many types of materials required by industry are supplied in large quantities by rolling the material about a hollow, substantially cylindrical core. Depending on the type of goods, the core may be formed from cardboard, plastic, metal or some other type of material. Alternatively, rolls of material can also be formed without a core. After the material has been wound onto a roll during manufacture, a desired number of individual rolls are packaged together and sent to the consumer.

[0004] When packaging rolled goods for shipment, warehouse handling or storage, it is a conventional practice to stack the individual rolls on a pallet such that the rolls are vertically-oriented relative to their longitudinal axis. In a typical pallet system, the rolls may be packaged in a number of individual rows with each row having a number of rolls. Depending upon the length of the rolls, multiple layers may be stacked onto a single pallet. Typically, once a pallet is formed, packaging material, such as stretch wrap or shrink-wrap and paperboard end protectors, are used to secure the pallet and prevent the rolls from tipping during storage and shipment.

[0005] Presently, a packaging system exists that includes a top cardboard or paperboard template that includes multiple die cut openings positioned to receive a core extension of each roll when the rolls are stacked on a pallet. The template interlocks the individual rolls by utilizing a plastic plug that passes through an opening in the template and into the core extension. When the template is installed on the rolls assembled on a pallet, the template prevents the rolls from tipping. However, this type of packaging system has a significant drawback in that once the template is removed, the individual rolls are no longer interlocked and can tip. Typically, the entire interlocking template must be removed from the top of a pallet of rolls prior to the rolls being unstacked. Additionally, when the rolls are initially stacked at the manufacturer, the template is not positioned on the pallet until the entire pallet has been formed.

[0006] When such a pallet is delivered to a consumer, the consumer removes the outer packaging material, including the top template, and removes the individual rolls of material one at a time. During the unloading of a pallet after the outer packaging material has been removed, it is possible for the rolls to be bumped and fall onto the floor from the pallet. Since some pallets are stacked such that the rolls are between six inches and four feet above the floor, a falling roll of material could be severely damaged upon contact with the floor. The damage to a roll could be so severe that the entire roll would need to be scrapped.

[0007] In addition to the problems identified above, currently available packaging system typically require many separate, individual components to provide an interlock between the plurality of stacked, vertical rolls. The numerous parts required increases the packaging costs of the rolls of material. Further, once the rolls have been unloaded, the numerous packaging materials required to interlock the rolls of vertically aligned material creates a significant amount of scrap material that must be disposed of by the consumer.

[0008] Therefore, a need exists for a packaging system that allows vertical stacked rolls of material to be interlocked with each other to prevent tipping of the individual rolls during either the stacking or unstacking process. Further, a need exists for a packaging system that allows individual rolls from the pallet to be removed while allowing the remaining rolls in the pallet to be stabilized. Further, a need exists for a packaging system that is inexpensive and easy to install.

SUMMARY OF THE INVENTION

[0009] The present invention generally relates to a packaging system for stabilizing a plurality of vertically-oriented rolls on a pallet. The packaging system of the present invention allows the rolls to be removed from the pallet individually while maintaining the stability of the remaining rolls on the pallet.

[0010] The packaging system of the present invention includes a plurality of individual interlocking devices that can be configured based on the application such that one size will fill most applications by bending or folding in the appropriate position. Once the interlocking device has been properly sized, the interlocking devices are positioned between a pair of rolls on the pallet. The interlocking devices extend between the open cores of a pair of rolls and interlock a pair of rolls to each other. The interlocking devices are positioned between the rolls on the pallet to create a lattice extending between the roll cores such that the rolls are adequately stabilized.

[0011] During the initial formation of the pallet, an interlocking device is positioned between each roll and another roll on the pallet as each roll is added to the pallet. In this manner, the pallet is stabilized during the entire time it is being constructed, unlike the packaging system of the prior art. Likewise, when the pallet of vertically-oriented rolls is disassembled, the individual interlocking devices are sequentially removed only as individual rolls are removed to allow the pallet to maintain its stabilization while allowing the individual rolls to be removed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The drawings illustrate the best mode presently contemplated of carrying out the invention.

[0013] In the drawings:

[0014]FIG. 1 is a perspective view of a pallet including a plurality of vertical rolls supported utilizing the packaging and stabilizing system of the prior art;

[0015]FIG. 2 is a section view taken along line 2-2 of FIG. 1 illustrating the interaction between the packaging system of the prior art and one of the vertical rolls of material;

[0016]FIG. 3 is a partial perspective view illustrating the insertion of one of the interlocking devices of the packaging and stabilizing system of the present invention between a pair of vertical rolls;

[0017]FIG. 4 is a top view illustrating a first configuration for a plurality of the interlocking devices of the packaging and stabilizing system of the present invention;

[0018]FIG. 5 is a magnified view taken along line 5-5 of FIG. 4 illustrating the interaction between three of the interlocking devices within a single vertical roll;

[0019]FIG. 6 is front view of the interlocking device in its stacking condition;

[0020]FIG. 7 is a top view illustrating a second configuration for the interlocking devices of the packaging and stabilizing system of the present invention;

[0021]FIG. 8 is a perspective view illustrating an alternate packaging and stabilizing system in accordance with the present invention;

[0022]FIG. 9 is a section view taken along line 9-9 of FIG. 8; and

[0023]FIG. 10 is a perspective view of a backing member used with the alternate embodiment of the packaging and stabilizing system of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0024] Referring first to FIG. 1, thereshown is a prior art packaging and stabilizing system 10. The prior art packaging system 10 is utilized to stabilize a pallet of closely spaced rolls 12 for shipping. Each of the rolls 12 is vertically-oriented for shipment.

[0025] As illustrated in FIG. 1, each of the rolls 12 is supported at its lower end by a bottom template 14 having a series of die cut openings 16. The die cut openings 16 are each sized to receive a core extension that extends past the lower edge of the film wound upon each of the rolls 12. The bottom template 14, in turn, is supported upon the pallet 18 for shipping.

[0026] Once the pallet of rolls 12 has been assembled onto the bottom template 14, a top template 20 is positioned on the top end of each roll 12 to secure the rolls in an ordered, packaged condition. As illustrated in FIG. 1, the top template 20 includes a series of die cut openings 22 each sized to receive an upper core extension 23 formed on each of the rolls 12. As illustrated in FIG. 2, once the top template 20 has been positioned as shown, an individual backing member 24 and end plug 26 are inserted into each of the core extensions 23 to secure the top template 20 in the position as shown. In the preferred embodiment of the invention, the bottom template 14, the top template 20 and the backing members 24 are all formed from cardboard or paperboard, while the end plug 26 is formed from a plastic material.

[0027] Although the packaging system 10 shown in FIG. 1 is effective for stabilizing a pallet of vertically-oriented rolls during shipment, significant drawbacks exist during the assembly and disassembly of the pallet. As can be understood in FIG. 1, when a roll 12 is to be removed from the pallet, all of the individual end plugs 26 and backing members 24 must first be removed from the cores of the plurality of rolls 12. Once all of the end plugs 26 and backing members 24 have been removed, the top template 20 can be lifted from the pallet and the rolls 12 removed individually.

[0028] As can be understood in FIG. 1, once the top template 20 has been removed, the rolls of material are no longer stabilized and are thus subject to tipping. This condition exists both during the initial stacking and subsequent unstacking of the rolls to form a pallet for shipment. Additionally, the packaging system 10 of the prior art includes many individual components, including the top template 20, the plurality of individual backing members 24, and end plugs 26 that must be stored prior to assembly and disposed of once the pallet has been unstacked.

[0029] Referring now to FIG. 3, thereshown is a first embodiment of the packaging and stabilizing system 30 of the present invention. The packaging system 30 provides a system for stabilizing a plurality of individual rolls 12 loaded onto a pallet while allowing the individual rolls 12 to be removed from the pallet one at a time while simultaneously maintaining stability for the remaining rolls on the pallet. Additionally, the packaging system 30 of the present invention allows the loaded rolls to be stabilized during the formation of the pallet as each individual roll is added to the pallet.

[0030] As illustrated in FIG. 3, each individual roll 12 includes a core extension 32 that extends above the top edge surface 34 of the roll. The core extension 32 in the preferred embodiment of the invention extends approximately ¼ to one inch above the top edge surface 34 and defines an open center 36 that extends along the entire longitudinal length of the roll 12. Alternatively, the core may be flush with the top edge surface 34.

[0031] In accordance with the present invention, the packaging system 30 includes a plurality of individual interlocking devices 38 that each extend between the core of a pair of adjacent rolls. Each interlocking device 38 secures a pair of interlocking rolls to each other such that the plurality of interlocking devices 38 create a lattice pattern to provide stability for the pallet of rolls during assembly, packaging, shipment and disassembly of the pallet.

[0032] As can be seen in FIG. 5, more than one interlocking device 38 can be positioned in a core 32 of an individual roll 12. Thus, an individual roll can be interlocked with more than one adjacent roll such that the series of interlocking devices 38 create a stabilized pallet of rolls.

[0033] Referring now to FIGS. 3 and 6, thereshown is the preferred embodiment of the interlocking device 38 in accordance with the present invention. The interlocking device 38 is formed from a single sheet of die-cut cardboard or paperboard material. The devices 38 include a spanning section 40 sized to extend between a pair of adjacent cores when the outer diameters of the rolls 12 are positioned in contact with each other.

[0034] As shown in FIG. 3, the spanning section 40 is connected between a pair of vertical legs 42 and 44. The vertical legs 42 and 44 each extend into the core of one of the rolls to support the spanning section 40 between a pair of rolls. In the preferred embodiment of the invention, each of the vertical legs 42, 44 includes a pair of wings 46 and 48 that engage the inner surface of the core of one of the rolls to help in retaining the vertical legs 42, 44 within the respective hollow core. In the preferred embodiment of the invention illustrated in FIG. 6, the spanning section 40 has a length of approximately {fraction (7 3/8)} inches as measured between the first end 52 and the second end 54 of the spanning section 40.

[0035] Referring back to FIG. 6, the interlocking device 38 includes an intermediate fold line 50 that allows the length of the spanning section 40 to be adjusted. In the embodiment of the invention illustrated in FIG. 6, the fold line 50 is {fraction (5 3/4)} inches from the first end. However, it should be understood that the position of the fold line 50 can be modified depending upon the preferred distance between the cores of the rolls to be stacked on a pallet.

[0036] Referring back to FIG. 6, each of the vertical legs 42, 44 has a length of approximately 6 inches, while the wings 46 and 48 have a width of approximately {fraction (1 5/8)} inches from the fold lines 56, 58 to the outer edges 59, 61, respectively. Each wing includes a tapered corner 63 to aid in guiding the vertical legs 42, 44 into the roll core. The width of the spanning section 40 is approximately two inches in the preferred embodiment of the invention. Although specific measurements for the sections of the interlocking device 38 are presented, it should be understood that the physical dimensions of the interlocking device 38 can be modified depending upon the roll size and the configuration of the rolls on a pallet. The measurements given are not meant to be limiting but are merely presented for illustrative purposes.

[0037] As can be understood in a comparison of FIGS. 3 and 6, the interlocking device 38 is die-cut from a single sheet of cardboard and is created in a flat, storage condition shown in FIG. 6. In the storage condition shown in FIG. 6, multiple interlocking devices 38 can be stacked on top of each other and thus occupy a small space. Thus, before the interlocking devices 38 are used, the interlocking devices can be compactly stacked and stored.

[0038] When the interlocking device 38 is to be used, the interlocking device 38 is folded along the first end 52 and the second end 54 to define the vertical legs 42 and 44, as shown in FIG. 3. Next, the wings 46 and 48 are folded along their respective fold lines 56 and 58 (FIG. 6) such that the interlocking device 38 is in the operating condition shown in FIG. 3. As discussed previously, the interlocking device 38 can be folded along line 50, depending upon the diameter of rolls being stacked utilizing the system of the present invention.

[0039] Referring back to FIGS. 3 and 4, assembly of a pallet of vertically-oriented rolls utilizing the packaging system 30 of the present invention will now be described. Initially, one of the rolls 12 a is positioned on a pallet in a vertical orientation. After the first roll 12 a has been positioned, a second roll 12 b is placed adjacent to the first roll 12 a and an interlocking device 38 a is positioned between the two adjacent rolls to secure the rolls to each other. Another roll 12 c is then placed on the pallet and yet another individual interlocking device 38 b is used to secure the newly placed roll 12 c to the prior placed roll 12 a. This process continues until the interlocking devices 38 are arranged in a lattice pattern and the entire pallet of vertically-oriented rolls are assembled, as shown in FIG. 4.

[0040] Referring now to FIG. 5, once the entire pallet of vertically-oriented rolls are assembled, several of the rolls, such as roll 12 c, receive multiple interlocking devices 38. As shown in FIG. 5, roll 12 c includes three interlocking devices 38 such that the roll 12 c aids in stabilizing more than one row of the rolls assembled on the pallet. As can be seen in FIG. 5, the wings 46, 48 of each of the interlocking devices 38 are received within the open center 36 to hold the interlocking device 38 in place. In the pallet configuration shown in FIG. 4, the pallet includes four rows each including five rows of material. Alternatively, as illustrated in FIG. 7, the pallet can be arranged such that the pallet includes five rows of rolls where each row includes five rolls. In the packaging arrangement shown in FIG. 7, the rolls are closely spaced and provide an alternate method of packaging rolls on a pallet. In the packaging arrangement shown in FIG. 7, the interlocking devices 38 are utilized in a lattice pattern to stabilize the rows and thus illustrate the flexibility of the packaging system of the present invention.

[0041] Once the pallet of rolls is assembled, as shown in FIGS. 4 and 7, the series of individual interlocking devices 38 provide stability for the entire pallet such that the pallet can be shipped without fear of tipping of any of the individual rolls.

[0042] Once the pallet of rolls is at its desired location, each of the rolls 12 can be removed without disrupting the stability of the remaining rolls on the pallet. For example, to remove individual roll 12 d (FIG. 4), the interlocking devices 38 c and 38 d are removed such that the lattice of interlocking devices to the roll 12 d is only partially broken. Once the interlocking devices 38 c and 38 d are removed from the roll core of the roll 12 d, the roll 12 d can be lifted from the pallet while the lattice pattern between the remaining rolls on the pallet continues to stabilize the pallet to prevent tipping. This process is repeated for each of the rolls on the pallet until the pallet has been completely unloaded.

[0043] Referring now to FIGS. 8-10, thereshown is a second embodiment of the packaging system of the present invention. In the second embodiment of the packaging system 60, an alternate type of interlocking device is utilized to stabilize the rolls on the pallet. In the second embodiment of the packaging system 60, a sheet of plastic 62 is draped over the top ends of each roll 12 as the rolls are added to the pallet. As illustrated in FIG. 9, after the sheet of plastic material 62 has been installed, a backing member 64, having a plurality of extending tabs 66 extending from a flat face 67, is inserted into the core 68 of the roll 12. As illustrated in FIG. 10, the tabs 66 include end points 70 that pierce the plastic sheet 62. Once the backing member 64 is in place, an end plug 66 is inserted into the core to lock the core in place relative to the sheet of plastic material 62.

[0044] Referring back to FIG. 8, once the pallet has been assembled, the sheet of plastic material 62 acts as an interlocking device between the individual rolls of material.

[0045] Once the pallet of rolls has been delivered to a desired location, each of the individual rolls can be removed from the pallet by cutting the plastic sheet 62 around the roll being removed or by simply folding back the plastic sheet after the core plug 66 and backing member 64 have been removed. Once the plastic sheet 62 has been cut or folded, the individual roll can be removed and the backing member 64 and end plug 66 discarded.

[0046] As can be understood in FIG. 8, when an individual roll is removed, the remaining portion of the plastic sheet 62 maintains the stability of the remaining rolls to prevent the rolls from tipping. In the preferred embodiment of the invention, the plastic sheet 62 is formed from a clear material such that the plastic material can be cut or folded without damaging the rolls.

[0047] Although not illustrated in the Figures, another alternate embodiment of the invention is contemplated in which individual rubber band-type elements can be used between the core extensions of adjacent rolls. The rubber band elements would replace the individual interlocking devices 38 shown in FIG. 3. It is contemplated that a rubber band device would extend between adjacent rolls and that several rolls in the pallet may have more than one rubber band extending around its core extension. Like the interlocking devices 38 shown in FIG. 3, rubber bands would allow each individual roll to be removed separately while maintaining the stability of the entire pallet.

[0048] In addition, it is contemplated by the inventor that the cardboard or paperboard interlocking devices 38 shown in FIG. 3 could be replaced by a plastic U-clip having a pair of vertical legs and a spanning section. A plastic U-clip would function identically to the interlocking devices 38 shown in FIG. 3 and would provide the required stability and individual removability of the rolls of material.

[0049] Although several embodiments of the invention are described in the present disclosure, it is contemplated by the inventor that other interlocking devices are within the scope of the present invention. The interlocking devices of the present invention provide stability for a pallet of vertically-oriented rolls while allowing the rolls to be individually removed without disrupting the overall stability of the remaining rolls. Further, the packaging system of the present invention reduces the number of discarded components as compared to the prior art packaging system 10 illustrated in FIG. 1.

[0050] Having described the presently preferred embodiments, it is to be understood that the invention may be otherwise embodied within the scope of the appended claims. 

What is claimed is:
 1. A method of stabilizing a plurality of rolls on a pallet, each roll being vertically-oriented and having a core extending therethrough, the method comprising the steps of: positioning a plurality of rolls on the pallet, each roll being vertically-oriented; providing a plurality of independent interlocking devices; inserting each of the interlocking devices between the cores of a pair of adjacent rolls on the pallet; arranging the plurality of interlocking devices in a lattice pattern to stabilize the plurality of rolls on the pallet; wherein each of the interlocking devices are separate from the remaining interlocking devices and can be inserted and removed individually.
 2. The method of claim I wherein the plurality of rolls are positioned in a plurality of rows, wherein at least one interlocking device extends between the rolls of adjacent rows.
 3. The method of claim 1 wherein the interlocking devices are positioned between the rolls as the rolls are sequentially positioned on the pallet.
 4. The method of claim 1 wherein the lattice pattern of the interlocking devices is arranged such that each roll is coupled to at least two other rolls on the pallet.
 5. The method of claim 1 wherein the interlocking devices each include a spanning section extending between two spaced vertical legs, wherein the vertical legs are inserted into the cores of the rolls.
 6. The method of claim 5 further comprising the step of modifying the length of the spanning section prior to insertion of the interlocking device into the core of the rolls.
 7. The method of claim 5 wherein the step of modifying the length of the spanning section includes bending the spanning section along a fold line to modify the length of the spanning section.
 8. A method of stacking and unstacking a plurality of rolls on a pallet, each roll being vertically-oriented and having a core extending therethrough, the method comprising the steps of: sequentially placing the plurality of rolls on the pallet to define a plurality of rows; inserting an interlocking device between each roll and at least one other of the plurality of rolls as each roll is placed onto the pallet, such that each roll is stabilized prior to additional rolls being placed on the pallet; arranging the plurality of interlocking devices in a lattice pattern among the plurality of rolls to stabilize the plurality of rolls on the pallet, wherein the lattice pattern is arranged such that each roll is coupled to at least two other rolls on the pallet and at least one interlocking device extends between rolls of adjacent rows; and removing all of the interlocking devices from the core of the roll to be removed from the pallet, wherein the interlocking devices of the lattice pattern remain between the rolls remaining on the pallet to stabilize the rolls.
 9. The method of claim 8 wherein each of the interlocking devices are independent from the remaining interlocking devices such that each of the interlocking devices can be individually inserted and removed between the plurality of rolls on the pallet.
 10. The method of claim 8 wherein the interlocking devices each include a spanning section extending between two spaced vertical legs, wherein the vertical legs are inserted into the cores of the rolls.
 11. The method of claim 10 further comprising the step of modifying the length of the spanning section prior to insertion of the interlocking device into the core of the roll.
 12. The method of claim 11 wherein the step of modifying the length of the spanning section includes bending the spanning section along a fold line.
 13. An interlocking device for stabilizing a plurality of rolls on a pallet, each roll being vertically-oriented and having a core extending therethrough, the interlocking device comprising: a spanning section extending between a first end and a second end; a first vertical leg connected to the first end of the spanning section; a second vertical leg connected to the second end of the spanning section, wherein the first vertical leg and the second vertical leg are configured to be received within the core of one of the plurality of rolls, wherein the spanning section, the first vertical leg and the second vertical leg are coplanar with each other in a stacking condition and wherein the first vertical leg and the second vertical leg are perpendicular to the spanning section in an operating condition.
 14. The interlocking device of claim 13 wherein the spanning section includes at least one fold line such that the length of the spanning section can be modified by folding the spanning section along the fold line.
 15. The interlocking device of claim 13 further comprising a pair of wings each coupled to one of the first and second vertical legs, wherein the wings are generally coplanar with the spanning section in the storage condition.
 16. The interlocking device of claim 13 wherein the spanning section, first vertical leg and the second vertical leg are integrally formed from cardboard. 